Centrifugal Aluminum Chloride Generator

ABSTRACT

A metal chloride generator is provided. The metal chloride generator is a metal chloride centrifugal reactor that can be operated under conditions sufficient to cause metal particles and chlorine in the generator to be brought into contact with one another and react using centrifugal force to form metal chloride. A process for manufacturing titanium dioxide that utilizes the metal chloride generator is also provided.

BACKGROUND

Titanium dioxide is a well-known pigment and white opacifying agent. Forexample, titanium dioxide is used as a pigment in connection withcoating formulations (including paint and ink formulations), papercompositions, polymer compositions and other products. Titanium dioxidepigments can be manufactured by either the sulfate process or thechloride process. Regardless of the manufacturing process used, thepigments are typically produced in powder form.

In the chloride process for manufacturing titanium dioxide, a drytitanium dioxide ore (for example, rutile or high-grade ilmenite) is fedinto a chlorinator together with a carbon source (for example, coke) andchlorine and reacted at a high temperature to produce titaniumtetrachloride (TiCl₄) in vapor form. The gaseous titanium tetrachlorideis condensed into liquid form and then purified to remove impuritiestherefrom. The purified titanium tetrachloride is then vaporized andreacted with oxygen in the vapor phase at a high temperature to producetitanium dioxide particles and gaseous reaction products. In order toachieve the necessary high temperature in the oxidizer, the titaniumtetrachloride vapor and oxygen gas stream are usually preheated beforebeing introduced into the oxidizer. Following the oxidation step, thetitanium dioxide and gaseous reaction products are cooled and thetitanium dioxide particles are recovered.

The recovered titanium dioxide particles are usually further processedbefore being sold and transported for use as a pigment. For example,depending on the anticipated end use application, the finishing processtypically entails coating the titanium dioxide particles with one ormore metal oxides to enhance the light scattering efficiency anddurability of the pigment and impart other desired properties andcharacteristics thereto.

A metal chloride such as aluminum chloride is typically added to thetitanium tetrachloride vapor in the oxidation reactor to incorporate ametal oxide into the crystalline lattice structure of the titaniumdioxide. The metal oxide promotes rutilization of the titanium dioxide.It also enhances the durability of the finished pigment.

Metal chloride for use in a titanium halide vapor phase oxidationprocess is generally obtained in one of two ways: 1) by purchasing itfrom a commercial vendor; or 2) by generating it in situ. Each way hasits advantages and disadvantages.

For example, pre-existing (e.g., purchased) metal chloride does notrequire the expense of the equipment necessary for generating the metalchloride in situ. However, pre-existing (e.g., purchased) metal chloridemust first be dissolved into the condensed liquid titanium halide. Thistypically requires the titanium halide to be heated. The dissolutionprocess can lengthen the time of the overall production cycle. Also, acommercial grade, pre-existing metal chloride such as aluminum chloridecan contain impurities that react with the titanium halide and produceproblematic deposits on the walls of the titanium halide vaporizer.Further, the mixture of the metal chloride and the titanium halide canbe corrosive, which typically requires the oxidation reactor and relatedequipment to be lined with costly corrosion-resistant material.

The aluminum chloride can be generated in situ by various methods. Forexample, the metal chloride (for example, aluminum chloride) can begenerated in a fluid bed reactor. In such a reactor, for example, amixed stream of chlorine gas and titanium halide vapor from thevaporizer or preheater (depending on the sequence in which suchequipment is used) can be introduced into a bed of solid metal (forexample, solid aluminum) pellets in the bottom of the reactor and causedto flow vertically in the form of bubbles and interstitial gas. Thebubbles and interstitial gas contact the metal pellets which cause thechlorine and metal to react to form metal chloride vapor. Blow oversolid metal (for example, solid aluminum) particles can exit the fluidbed reactor as blow over. A sand bed is also typically included in thereactor in order to scour the surface of the aluminum or other metalpellets to break an aluminum oxide or other metal oxide coating that isgenerally inherently on the surfaces of the pellets.

The size of a fluid bed metal chloride generator is generally determinedby the size of the metal particles allowed to exit the reactor as blowover and the exothermicity of the reaction between the metal andchlorine. The desired blow over metal particle size dictates the spacevelocity and transport disengagement height of the fluid bed. Usually,the particle size is chosen to be relatively small due to concerns oferosion and corrosion of downstream equipment. For example, the reactionof aluminum and chlorine is so exothermic that at typical additionlevels, virtually the entire titanium halide vapor stream is run throughthe fluid bed metal chloride generator to serve as a heat sink for theprocess to keep the reaction temperature under control as dictated bythe melting point of aluminum. Due to the exothermic nature of thereaction, the overall rate of addition of the aluminum and chlorine tothe reactor is also a factor in determining the size of the reactorneeded.

Normally, in order to produce a sufficient amount of metal chloride toprovide the desired concentration of metal oxide in the titanium dioxidepigment, the fluid bed reactor is fairly large. A decrease in theparticle size of the metal generally means an increase in the size ofthe reactor required. For example, in many cases, a fluid bed metalchloride generator on a titanium dioxide production line will be 16 feetin height and over three feet in diameter. Due to the corrosive natureof a titanium halide and metal chloride mixture, the reactor mustgenerally be made of exotic alloys and be refractory lined. As a result,large fluid bed reactors can be costly due to capital, operational andmaintenance costs.

SUMMARY

In accordance with the present disclosure, a metal chloride generator isprovided. The metal chloride generator is a metal chloride centrifugalreactor. In one embodiment, the metal chloride generator disclosedherein comprises:

-   -   a. a reactor housing, the reactor housing including an inside        surface, an outside surface, a top portion, a bottom portion, a        sidewall connecting the top portion and the bottom portion        together, and an interior;    -   b. a cylindrical reaction chamber positioned within the interior        of the reactor housing, the reaction chamber including an inside        surface, an outside surface, a top, a bottom, a cylindrical side        wall connecting the top and the bottom together and an interior,        the interior of the reaction chamber having a top half and a        bottom half;    -   c. a reactant inlet conduit extending through the sidewall of        the reactor housing and the sidewall of the reaction chamber and        including an inside surface, an outside surface and an interior,        the reactant inlet conduit also including a first opening for        receiving at least one reaction component from a location        outside of the reactor housing and a second opening for        discharging the reaction component into the reaction chamber,        the second opening of the reactant inlet conduit being flush        with the inside surface of the cylindrical sidewall of the        reaction chamber and opening into the interior of the reaction        chamber; and    -   d. a reaction product outlet conduit extending through the top        of the reaction chamber and the top of the reactor housing and        including an inside surface, an outside surface and an interior,        the reaction product outlet conduit also including a first        opening for receiving at least one reaction product from the        interior of the reaction chamber and a second opening for        discharging the reaction product to a location outside of the        reactor housing.

In another embodiment of the metal chloride generator, at least one ofthe reaction chamber, the reactant inlet conduit, and the reactionproduct outlet conduit includes a refractory lining attached to theinside surface thereof, the refractory lining having an inside surfacefacing the interior of the reaction chamber, reactant inlet conduit orreaction product outlet conduit that has a texture rough enough to breakmetal oxide layers on the metal particles.

In accordance with the present disclosure, a process for manufacturingtitanium dioxide is also provided. In a first embodiment, the process isa chloride process for manufacturing titanium dioxide, comprising:

-   -   a. introducing titanium dioxide ore, a carbon source and        chlorine into a chlorinator;    -   b. operating the chlorinator under conditions sufficient to        cause titanium dioxide ore, the carbon source and chlorine in        the chlorinator to react to form titanium tetrachloride;    -   c. introducing metal particles and chlorine into a metal        chloride generator, wherein the metal chloride generator is a        metal chloride centrifugal reactor;    -   d. operating the metal chloride generator under conditions        sufficient to cause metal particles and chlorine in the        generator to be brought into contact with one another and react        using centrifugal force to form metal chloride;    -   e. introducing titanium tetrachloride formed in the chlorinator,        metal chloride formed in the metal chloride generator and oxygen        into an oxidizer;    -   f. operating the oxidizer under conditions sufficient to oxidize        titanium tetrachloride and metal chloride in the oxidizer to        form titanium dioxide particles having a metal oxide        incorporated into their crystalline lattice structure; and    -   g. recovering titanium dioxide particles formed in the oxidizer.

In a second embodiment, the process is a process for manufacturingtitanium dioxide, comprising:

-   -   a. introducing metal particles and chlorine into a metal        chloride generator, wherein the metal chloride generator is a        metal chloride centrifugal reactor;    -   b. operating the metal chloride generator under conditions        sufficient to cause metal particles and chlorine in the        generator to be brought into contact with one another and react        using centrifugal force to form metal chloride;    -   c. introducing titanium halide, metal chloride formed in the        metal chloride generator and oxygen into an oxidizer;    -   d. operating the oxidizer under conditions sufficient to oxidize        titanium halide and metal chloride in the oxidizer to form        titanium dioxide particles having a metal oxide incorporated        their crystalline lattice structure; and    -   e. recovering titanium dioxide particles formed in the oxidizer.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included with this application illustrate certain aspectsof the embodiments described herein. However, the drawings should not beviewed as exclusive embodiments. The subject matter disclosed is capableof considerable modifications, alterations, combinations, andequivalents in form and function, as will occur to those skilled in theart with the benefit of this disclosure.

FIG. 1 is a perspective view of one embodiment of the centrifugalaluminum chloride generator disclosed herein.

FIG. 2A is a partial sectional view of the centrifugal aluminum chloridegenerator illustrated by FIG. 1 with a top inlet and a without a centralvortex finder.

FIG. 2B is a partial sectional view of the centrifugal aluminum chloridegenerator illustrated by FIG. 1 with a top inlet and a central vortexfinder extending a first distance from the top of the generator into thegenerator.

FIG. 2C is a partial sectional view of the centrifugal aluminum chloridegenerator illustrated by FIG. 1 with a top inlet and a central vortexfinder extending a second distance from the top of the generator intothe generator.

FIG. 2D is a partial sectional view of the centrifugal aluminum chloridegenerator illustrated by FIG. 1 with a bottom inlet and without acentral vortex finder.

FIG. 2E is a partial sectional view of the centrifugal aluminum chloridegenerator illustrated by FIG. 1 with a bottom inlet and a central vortexfinder extending a first distance from the top of the generator into thegenerator.

FIG. 3 is another partial sectional view of the centrifugal aluminumchloride generator illustrated by FIG. 2A.

FIG. 4A is a detail view taken from section 4A of FIG. 3.

FIG. 4B is a detail view taken from section 4B of FIG. 3.

FIG. 4C is a detail view taken from section 4C of FIG. 2C.

FIGS. 5-8 illustrate the results of a computational fluid dynamics (CFD)analysis carried out with respect to the aluminum chloride generatorillustrated by FIGS. 1-3 and 4A-4C.

FIG. 9 is a schematic diagram illustrating one embodiment of the processfor manufacturing titanium dioxide disclosed herein.

FIG. 10 is a schematic diagram illustrating another embodiment of theprocess for manufacturing titanium dioxide disclosed herein.

DETAILED DESCRIPTION

The present disclosure may be understood more readily by reference tothis detailed description. For simplicity and clarity of illustration,where appropriate, reference numerals may be repeated among thedifferent figures to indicate corresponding or analogous elements. Inaddition, numerous specific details are set forth in order to provide athorough understanding of the various embodiments described herein.However, it will be understood by those of ordinary skill in the artthat the embodiments described herein can be practiced without thesespecific details. In other instances, methods, procedures and componentshave not been described in detail so as not to obscure the relatedrelevant feature being described. Also, the description is not to beconsidered as limiting the scope of the embodiments described herein.The drawings are not necessarily to scale and the proportions of certainparts have been exaggerated to better illustrate details and features ofthe present disclosure.

In one aspect, the present disclosure provides a metal chloridegenerator. In another aspect, the present disclosure provides a processfor manufacturing titanium dioxide.

The metal chloride generator disclosed herein is a metal chloridecentrifugal reactor. As used herein and in the appended claims, a metalchloride centrifugal reactor means a reactor that uses centrifugalforces to facilitate the reaction of a solid metal and chlorine gas toform a metal chloride, and to separate the metal chloride from othercomponents in the reactor. The centrifugal forces allow the chlorine gasand solid metal particles to react while preventing small unreactedmetal particles in the generator from being carried out of the reactoras blow over. The metal chloride generator can be used as a stand alonemetal chloride generator or can be used in situ in any process in whicha metal chloride is needed. As used herein and in the appended claims,“attached to” a surface or component means attached, directly orindirectly, to the surface or component.

In one embodiment, the metal chloride generator disclosed herein is foruse in generating metal chloride in situ in a process for manufacturingtitanium dioxide. For example, the metal chloride generator can be usedto circumvent the size constraints and design parameters associated withconventional fluidized bed reactors currently used to generate metalchlorides in situ in a chloride process for manufacturing titaniumdioxide.

Referring now to the drawings, and particularly to FIGS. 1-4, oneembodiment of the metal chloride generator of the present disclosure,generally designated by the reference number 10, will be described. Themetal chloride generator 10 comprises:

-   -   a. a reactor housing 12, the reactor housing including an inside        surface 14, an outside surface 16, a top portion 18, a bottom        portion 20, a sidewall 22 connecting the top portion 18 and the        bottom portion 20, and an interior 24;    -   b. a cylindrical reaction chamber 28 positioned within the        interior 24 of the reactor housing 12, the reaction chamber 28        including an inside surface 32, an outside surface 34, a top 36,        a bottom 38, a cylindrical sidewall 40 connecting the top 36 and        the bottom 38 together and an interior 44, the interior 44 of        the reaction chamber 28 having a top half 46 and a bottom half        48;    -   c. a reactant inlet conduit 50 extending through the sidewall 22        of the reactor housing 12 and the sidewall 40 of the reaction        chamber 28 and including an inside surface 51, an outside        surface 52 and an interior 53, the reactant inlet conduit 50        also including a first opening 54 for receiving at least one        reaction component from a location 56 outside of the reactor        housing 12, and a second opening 60 for discharging the reaction        component into the reaction chamber 28, the second opening 60 of        the reactant inlet conduit 50 being flush with the inside        surface 32 of the cylindrical sidewall 40 of the reaction        chamber 28 and opening into the interior 44 of the reaction        chamber 28; and    -   d. a reaction product outlet conduit 62 extending through the        top 36 of the reaction chamber 28 and the top portion 18 of the        reactor housing 12 and including an inside surface 63, an        outside surface 64 and an interior 65, the reaction product        outlet conduit 62 including a first opening 66 for receiving at        least one reaction product from the interior 44 of the reaction        chamber 28 and a second opening 68 for discharging the reaction        product to a location 70 outside of the reactor housing.

The reactor housing 12 is cylindrical in shape and supported on theground by a stand assembly 72. The stand assembly 72 supports the metalchloride generator 10 on the ground or other surface (not shown). Thestand assembly 72 includes a plurality of leg members 74. A pair ofopposing flange assemblies 78 are attached to the outside surface 16 ofthe reactor housing 12 adjacent to the top portion 18 and the sidewall22 of the reactor housing 12 for allowing the top portion 18 to beremoved from the reactor housing 12. The removable top portion 18 of thereactor housing 12 allows access to the interior 44 of the reactionchamber 12.

A corrosion-resistant liner 84 having an inside surface 86 and anoutside surface 88 is attached to the reactor housing 12. The outsidesurface 88 of the corrosion-resistant liner 84 is attached to the insidesurface 14 of the reactor housing 12.

The cylindrical reaction chamber 28 is cylindrical in shape andpositioned in a center portion 90 of the reactor housing 12. The insidesurface 32 of the reaction chamber 28 is surrounded by a refractorylining 92 that has an inside surface 94 and an outside surface 96. Theinside surface 94 of the refractory lining 92 faces the interior 44 ofthe reaction chamber 28.

The refractory lining 92 is surrounded by an insulation layer 100, whichincludes an inside surface 102 and an outside surface 104, a sidewall106, a top 108 and a bottom 110. The inside surface 102 of theinsulation layer 100 is attached to the outside surface 96 of therefractory lining 92. For example, the outside surface 104 of thesidewall 106 of the insulation layer 100 is attached to the insidesurface 86 of the corrosion-resistant liner 84.

The reactant inlet conduit 50 is a cylindrical conduit. The insidesurface 51 of the reactant inlet conduit 50 is surrounded by arefractory lining 120 that has an inside surface 122 and an outsidesurface 124. The inside surface 122 of the refractory lining 120 facesthe interior 53 of the reactant inlet conduit 50.

An insulation layer 130 having an inside surface 132 and an outsidesurface 134 surrounds the refractory lining 120. The inside surface 132of the insulation layer 130 is attached to the outside surface 124 ofthe refractory lining 120. As best shown by FIG. 4B, acorrosion-resistant liner 140 having an inside surface 142 and anoutside surface 144 surrounds the insulation layer 130. The insidesurface 142 of the corrosion-resistant liner 140 is attached to theoutside surface 134 of the insulation layer 130.

The reactant inlet conduit 50 receives at least one reaction component(for example, all of the reaction components) from a location 56 outsideof the reactor housing 12 through the first opening 54 and dischargesthe reaction component (for example, all of the reaction components)through the second opening 60 into the reaction chamber 28. For example,the location 56 can be one or more other conduits (not shown) fluidlyconnected to sources of the reaction products (not shown). A flange 80can be used to connect the reactant inlet conduit 50 to another conduit.

As shown by FIGS. 1, 2A, 2B, 2C and 3, the second opening 60 of thereactant inlet conduit 50 opens into the top half 46 of the interior 44of the reaction chamber 28. In another embodiment, as shown by FIGS. 2Dand 2E, the second opening 60 of the reactant inlet conduit 50 opensinto the bottom half 48 of the interior 44 of the reaction chamber 28.For example, as shown by Example 1 below, it is better in some respectsfor the second opening 60 of the reactant inlet conduit 50 to open intothe top half 46 of the interior 44 of the reaction chamber 28.

The reaction product outlet conduit 62 is also a cylindrical conduit.The reaction product outlet conduit 62 is surrounded by a refractorylining 150 that has an inside surface 152 and an outside surface 154.The inside surface 152 of the refractory lining 150 faces the interior65 of the reactant inlet conduit 50.

An insulation layer 160 having an inside surface 162 and an outsidesurface 164 surrounds a portion 166 of the reaction product outletconduit 62 adjacent the second opening 68 thereof. The inside surface162 of the insulation layer 160 is attached to the outside surface 64 ofthe reaction product outlet conduit 62. As best shown by FIG. 4C, acorrosion-resistant liner 170 having an inside surface 172 and anoutside surface 174 surrounds the insulation layer 160. The insidesurface 172 of the corrosion-resistant liner 170 is attached to theoutside surface 164 of the insulation layer 160.

The reaction product outlet conduit 62 receives at least one reactionproduct (for example, all of the reaction products) from the interior 44of the reaction chamber 28 through the first opening 66 and dischargesthe reaction product (for example, all of the reaction products) throughthe second opening 68 to a location 70 outside of the reactor housing12. For example, the location 70 can be one or more other conduits (notshown) for conducting the reaction product to other equipment (notshown) for further processing. A flange 82 can be used to connect thereaction product outlet conduit 62 to another conduit.

As shown by FIGS. 2A, 2D and 3, the first opening 66 of the reactionproduct outlet conduit 62 is flush with the top 36 of the reactionchamber 28. As shown by FIGS. 2B, 2C and 2E, in another embodiment, thereaction product outlet conduit 62 extends from the top 36 of thereaction chamber 28 into the interior 44 of the reaction chamber 28 suchthat the first opening 66 of the reaction product outlet conduit 62 ispositioned within the interior 44 of the reaction chamber 28. In thisembodiment, for example, the distance that the reaction product outletconduit 62 extends into the interior 44 of the reaction chamber 28 canbe varied to change the position of the first opening 66 within theinterior 44 of the reaction chamber 28.

For example, as shown by FIGS. 2B and 2E, the reaction product outletconduit 62 extends less than half way into the interior 44 of thereaction chamber 28 such that the first opening 66 of the reactionproduct outlet conduit 62 is positioned within the top half 46 of theinterior 44 of the reaction chamber 28. For example, as shown by FIG.2C, the reaction product outlet conduit 62 extends more than half wayinto the interior 44 of the reaction chamber 28 such that the firstopening 66 of the reaction product outlet conduit 62 is positionedwithin the bottom half 48 of the interior 44 of the reaction chamber 28.In the same way, the first opening 66 can be placed in other positionswithin the interior 44 of the reaction chamber 28 as well.

For example, as shown by Example 1 below, it may work best in some casesfor the reaction product outlet conduit to extend less than half wayinto the interior 44 of the reaction chamber 28 such that the firstopening 66 of the reaction product outlet conduit 62 is positionedwithin the top half 46 of the interior 44 of the reaction chamber 28. Infact, in many cases, it may work best for the first opening 66 of thereaction product outlet conduit 62 to be flush with the top 36 of thereaction chamber 28.

The reactor housing 12 is formed of an Inconel alloy or an Inconel alloyclad carbon steel. The reaction chamber 28, the reactant inlet conduit50 and the reaction product outlet conduit 62 are formed of siliconcarbide or another corrosion-resistant ceramic material.

The corrosion-resistant liners 84, 140 and 170 are each formed of amaterial that is resistant to corrosion by the reactants added to thereaction chamber and the reaction products formed therein. For example,the corrosion-resistant liners 84, 140 and 170 can each be formed ofsilicon carbide or another corrosion-resistant ceramic material.

The insulation layers 100, 130 and 160 are each formed of a materialthat can help retain the heat that is generated by the reaction in thereaction chamber 28. For example, the insulation layers 100, 130 and 160can each be formed of a refractory tile or firebrick.

The refractory linings 92, 120, and 150 prevent wear and tear of thecomponents of the metal chloride generator 10 due to particle abrasionand corrosion. The refractory linings 92, 120, and 150 can serve otherfunctions as well. For example, metal (for example, aluminum) particlesadded to the reaction chamber 28 tend to have a metal oxide layer (forexample, an aluminum oxide layer in the case of aluminum) on theirsurfaces. In order to sustain the metal chloride reaction consistently,it can be necessary to break up such metal oxide layers on the metalparticles.

For example, one or more (for example, all) of the inside surfaces 94,122, and 152 of the refractory linings 92, 120 and 150 facing theinteriors 44, 53 and 65 of the reaction chamber 28, reactant inletconduit 50, and reaction product outlet conduit 62, respectively, canhave a texture that is rough enough to break up metal oxide layers onthe metal particles. The texture of the surfaces can provide thescouring necessary to break up any metal oxide layers on the metalparticles, thereby eliminating the need for sand or another scouringagent in the reaction chamber 28.

For example, one or more (for example, all) of the inside surfaces 94,122, and 152 of the refractory linings 92, 120 and 150 can have asurface roughness in the range of from about 0.01 μm to about 1000 μm.For example, one or more (for example, all) of the inside surfaces 94,122, and 152 of the refractory linings 92, 120 and 150 can have asurface roughness in the range of from about 0.96 μm to about 9.79 μm.As used herein and in the appended claims, the “surface roughness” of asurface means the length of the deviations in surface in the directionof the normal vector of the surface, as measured by a Mahr Pocket SurfPS1 surface tester. The larger the deviations, the rougher the surface.

For example, the refractory linings 92, 120, and 150 can be formed of aceramic material. For example, the refractory linings 92, 120, and 150can be formed of a silicon carbide (SiC) ceramic material. For example,ceramic materials such as a silicon carbide material not onlyeffectively protect the inside surfaces 94, 122, and 152 of the reactionchamber 28, reactant inlet conduit 50 and reaction product outletconduit 62 from wear and tear, but also have sufficient textures toprovide the scouring necessary to break the metal oxide layer on themetal particles. An example of such a material that is commerciallyavailable is Altron™ Alumina Bonded Silicon Carbide, sold by BlaschPrecision Ceramics, Inc. of Albany, N.Y.

As described below, the metal chloride generator 10 can be incorporatedinto a production line for producing titanium dioxide. The generatedmetal chloride can be mixed into the full flow of the titanium halidevapor or other titanium halide line feeding the oxidizer in order tohelp disperse the high heat of the metal chloride coming out of thealuminum chloride generator 10. For example, the titanium halide vaporcan be run through the metal chloride generator 10 during operation ofthe generator.

The cylindrical reaction chamber 28 operates as a centrifuge reactor. Achlorine gas stream is fed into the first opening 54 of the reactantinlet conduit 50. For example, a feed apparatus (not shown) can be usedto drop metal particles (for example, aluminum pellets) into thechlorine gas stream in the reactor inlet conduit 50. For example, thefeed apparatus can be a double valve arrangement, a dump valve, a rotaryvalve, a pressurized feeder or a screw feeder. The velocity of thechlorine gas stream carries the pellets into the reaction chamber 28.For example, the reaction components are tangentially injected throughthe first opening 54 of the reactant inlet conduit 50 into the interior24 of the reaction chamber 28 at a velocity and pressure sufficient tocause the reaction components to swirl around the inside surface 32 ofthe sidewall 40 of the reaction chamber and form a vortex in thereaction chamber.

The second opening 60 of the reactant inlet conduit 50 helps form thevortex of reaction components in the interior 24 of the reaction chamber28. The shape, configuration and position of the second opening 60 ofthe reactant inlet conduit 50 causes the reactants to be tangentiallyinjected (with respect to the surface 32) into the reaction chamber andtravel along the cylindrical wall when the reactants are injected intothe reaction chamber at a sufficient velocity and pressure. For example,as shown by FIG. 2A, the second opening 60 of the reactant inlet conduit50 is a cyclonic inlet that tapers toward the interior 44 of thereaction chamber 28 and is configured to tangentially inject thereactants with respect to the inside surface 32 of the cylindricalsidewall 40 of the reaction chamber. The second opening is flush withthe inside surface 32 of the cylindrical sidewall to facilitate thetangential injection.

For example, in order to assure that the metal particles added to thereaction chamber 28 of the generator 10 keep circulating in the reactionchamber, the reaction components can be injected through the firstopening 54 of the reactant inlet conduit 50 into the interior 24 of thereaction chamber 28 at a minimum injection velocity (a “minimum inletvelocity”). The minimum injection velocity is a function of the geometryof the reactor. For example, the minimum inlet velocity can be in therange of about 25 ft/sec to about 100 ft/sec. Due to flow effects, thealuminum chloride that is formed during the process (together withtitanium halide, for example, if titanium halide is introduced into thereactor to absorb heat) works its way down in the reaction chamber 28and outwardly from the inside surface 32 of the reaction chamber 28 intoa vortex in the reactor created by the centrifugal action. Once in thevortex, the aluminum chloride vapors (and titanium halide vapors, ifpresent) make their way into the reaction product outlet conduit 62 andexit the reaction chamber 28 and generator 10.

The centrifugal action created by the vortex in the reaction chamber 28applies centrifugal forces (for example, g-forces) to the metalparticles which holds smaller metal particles in the reaction chamber 28thereby making the reaction process more efficient and allowing asmaller reactor to be used. For example, aluminum reacts with chlorinegas in the reaction chamber 28 to form aluminum chloride vapor inaccordance with the following reaction:

Al (s)+3/2Cl₂ (g)→AlCl₃ (v)

For example, the temperature in the reaction chamber 28 can be keptabove the low temperature extreme of about 300° C., where thetemperature may not be sufficient to kick off the reaction, and belowthe high temperature extreme of the melting point of the metal (forexample, 660° C., which is the melting point of aluminum). The reactionbetween metal and chlorine in the reaction chamber is very exothermic.For example, when the generator 10 is used on a chloride process formanufacturing titanium dioxide, combining all or a portion of thetitanium halide gas stream with the chlorine gas stream fed into thereaction chamber 28 can help control the temperature of the reaction.The gaseous titanium halide stream absorbs heat thereby helping tocontrol the temperature of the overall reactant stream.

By extending from the top 36 of the reaction chamber 28 into theinterior 44 of the reaction chamber 28, the reaction product outletconduit 62 serves as a vortex finder, that is, the reaction productoutlet conduit 62 serves to position the first opening 66 in the vortexformed in the reaction chamber 28. By varying the distance in which thereaction product outlet conduit 62 extends into the interior 44 of thereaction chamber 28 to change the position of the first opening 66within the interior 44 of the reaction chamber 28, the optimum positionof the vortex finder can be determined. As shown by Example 1, in somecases, the process works better with no vortex finder at all, that is,when the first opening 66 of the reaction product outlet conduit 62 isflush with the top 36 of the reaction chamber 28.

The inherent surface roughness of the refractory linings 92, 120 and 150functions to scour aluminum particles to remove aluminum oxide from thesurfaces thereof. This eliminates the need for sand or other scour mediain the reaction chamber 28 and the associated wear problems potentiallycaused thereby.

The entire process, including the generation of metal chloride in thegenerator 10, is carried out on a continuous basis. The amount of metalchloride from the generator 10 that is added to the oxidizer 250 withthe titanium halide is sufficient to cause metal oxide to beincorporated into the lattice structure of the titanium dioxide formedin the oxidizer. For example, metal chloride from the generator 10 canbe added to the oxidizer 250 in an amount in the range of from about0.5% to about 1.5% by weight, based on the weight of the titaniumdioxide that is formed.

For example, aluminum, boron, zirconium, silicon, and phosphorous can bereacted with chlorine gas in the metal chloride generator 10 to formaluminum chloride (AlCl₃), boron trichloride (BCl₃), zirconium chloride(ZrCl₄), silicon chloride (SiCl₄) and phosphorus chloride (PCl₃),respectively. Various mixtures or alloys of the above metals includingaluminum-silicon alloys, aluminum-phosphorus alloys, aluminum-boronalloys, aluminum-zirconium alloys and combinations thereof can also bereacted with chlorine in the metal chloride generator 10 to form mixedmetal chloride precursor compounds.

FIGS. 5-8 illustrate the results of a computational fluid dynamics (CFD)analysis carried out with respect to the metal chloride generator 10,based on the reaction of chlorine gas and aluminum pellets to formaluminum chloride in the generator 10. This analysis shows, for example,the top entry configuration of the generator 10 (FIG. 5), the likelyflow pattern and reactant velocity in the generator 10 (FIG. 6), thepressure drop in the generator 10 (FIG. 7) and the particle retention inthe generator 10 (FIG. 8). The analysis is based on a reaction chamber28 that has an internal diameter of 32 inches, an internal height of 28inches and an external height of 31 inches, a reactant inlet conduit 50that has a 12 inch nominal inner diameter, and a reaction product outletconduit 62 that has a 9.2 inch inner diameter. The velocity associatedwith the reactant inlet conduit 50 is 86 ft/sec. The pressure drop inthe reaction chamber 28 is 0.6 psig. All particles over 100 μm areretained in the reaction chamber 28.

As indicated by FIG. 7, for example, the pressure drop within thereaction chamber 28 is fairly small, less than 1 psig. In comparison, atraditional fluid bed reactor requires a sufficient pressure drop acrossa flow distributor. For example, the pressure drop across the bed of afluid bed reactor can be 5 psi.

As indicated by FIG. 8, for example, the generator 10 will retainaluminum particles as small as 100 μm, which is well below the terminalvelocity size for a fluid bed generator (approximately 600 μm).

For example, in one embodiment, the aluminum chloride generator has thefollowing design parameters: (a) the tangential fluid flow velocitythrough the reactant inlet conduit 50 is between about 50 ft/sec toabout 200 ft/sec.; (b) the ratio between the inner diameter of thereaction chamber 28 to the inner diameter of the reactant inlet conduit50 is between 2:1 to 4:1; (c) the ratio between the height of thereaction chamber 28 to the inner diameter of the reactant inlet conduit50 is between 2:1 to 10:1; and (d) the ratio between the diameter of thereaction product outlet conduit 62 to the diameter of the reactant inletconduit 50 is between 1:1 to 2:1. With these design parameters, awell-developed centrifugal flow pattern is achieved resulting in a goodpressure drop and good particle retention, and allowing a relativelysmall reactor to be used. The aluminum chloride generator 10 iscompatible with an oxidizer that is capable of producing 7.5 metric tonsof titanium dioxide per hour.

Thus, the metal chloride generator 10 disclosed herein has a relativelycompact design when compared to conventional fluid bed metal chloridegenerators and can be used as an alternative thereto. A traditionalfluid bed aluminum chloride generator is approximately 16 feet high and3.3 feet in diameter. The metal chloride generator 10 can reduce thissize by 90% or more. This not only reduces the capital expensesassociates with generating aluminum chloride, but also reduces thefootprint and allows the generator 10 to be relatively easilyretrofitted into an existing plant. The metal chloride generator andprocesses disclosed herein can result in a decrease in the capitalexpenditures and operating expenditures associated with the manufactureof titanium dioxide pigments. The metal chloride generator can beretrofitted into existing operations including existing production linesfor producing titanium dioxide.

Referring now to FIG. 9, with reference to FIGS. 1-4, a first embodimentof the process for manufacturing titanium dioxide disclosed herein willbe described. In this embodiment, the process is a chloride process formanufacturing titanium dioxide, comprising:

-   -   a. introducing titanium dioxide ore, a carbon source and        chlorine into a chlorinator 200;    -   b. operating the chlorinator 200 under conditions sufficient to        cause titanium dioxide ore, the carbon source and chlorine in        the chlorinator 200 to react to form titanium halide (TiCl₄);    -   c. introducing metal particles and chlorine into a metal        chloride generator 220, wherein the metal chloride generator 220        is a metal chloride centrifugal reactor;    -   d. operating the metal chloride generator 220 under conditions        sufficient to cause metal particles and chlorine in the        generator to be brought into contact with one another and react        using centrifugal force to form metal chloride;    -   e. introducing titanium halide formed in the chlorinator 200,        metal chloride formed in the metal chloride generator 220 and        oxygen into an oxidizer 250;    -   f. operating the oxidizer 250 under conditions sufficient to        oxidize titanium halide and metal chloride in the oxidizer 250        to form titanium dioxide particles having a metal oxide        incorporated into their crystalline lattice structure and        gaseous reaction products; and    -   g. recovering titanium dioxide particles formed in the oxidizer        250.

For example, the titanium dioxide ore introduced into the chlorinator200 can be rutile, synthetic rutile, high-grade ilmenite, or titaniumslag. For example, the titanium dioxide ore introduced into thechlorinator 200 can be a 50:50 blend of synthetic rutile and titaniumslag.

Chlorinators useful for facilitating the reaction of titanium dioxideore, a carbon source and gaseous chlorine (Cl₂) to form titaniumtetrachloride in a chloride process for manufacturing titanium dioxideare known to those skilled in the art with the benefit of thisdisclosure. The titanium dioxide ore and carbon source can be conductedto and introduced into the chlorinator from one or more sources thereof(not shown) as known to those skilled in the art. As shown by FIG. 9,the chlorine conducted to and introduced into the chlorinator can bechlorine gas that is recycled from a subsequent reaction step.Alternatively, the chlorine gas can come from another source. As usedherein and in the appended claims, a carbon source means one or morecompounds capable of providing the carbon necessary to react withtitanium dioxide and chlorine to form titanium tetrachloride. Forexample, the carbon source can be coke.

As understood by those skilled in the art with the benefit of thisdisclosure, the chlorinator operates as a fluidized bed reactor. Thechlorinator 200 is operated under conditions sufficient to causetitanium dioxide ore, the carbon source and chlorine in the chlorinatorto react to form titanium tetrachloride. For example, the chlorinator200 is operated at a temperature in the range of from about 900° C. toabout 1000° C. The main chemical reactions that occur in the chlorinator200 are exemplified by reaction (1):

TiO₂+C+2Cl→TiCl₄+CO+CO₂  (1)

The gaseous titanium tetrachloride and other gaseous reaction productsformed in the chlorinator 200 are conducted to and introduced into acondenser 270. Condensers useful for condensing gaseous titaniumtetrachloride to liquid titanium tetrachloride (for example, by coolingthe gaseous titanium halide) are known to those skilled in the art withthe benefit of this disclosure. As understood by those skilled in theart with the benefit of this disclosure, the condenser 270 is operatedunder conditions sufficient to condense gaseous titanium tetrachlorideto liquid titanium tetrachloride.

Waste gas in the condenser 270 is conducted to and introduced into awaste gas scrubber 274, where it is scrubbed and discharged andconducted to another location for further processing or disposal.Hydrochloric acid (HCl) formed by the scrubbing process is dischargedfrom the waste gas scrubber 274 and conducted to another location forstorage or further processing.

Liquid titanium tetrachloride formed in the condenser 270 is conductedfrom the condenser 270 and introduced into purification processequipment 280 that can be used to purify the titanium tetrachloride. Forexample, the liquid titanium tetrachloride can be purified by treatingthe titanium tetrachloride with oils, distilling the titaniumtetrachloride and/or filtering the titanium tetrachloride. The processequipment 280 includes the necessary equipment to carry out one or moreof these steps.

The purified liquid titanium halide is then conducted from thepurification process equipment 280 and introduced into a storagecontainer 286. The purpose of the storage container 286 is to assurethat a supply of purified titanium tetrachloride is continuouslyavailable for the subsequent process steps.

Liquid titanium tetrachloride is then conducted from the storagecontainer 286 and introduced into a vaporizer 290. Vaporizers useful forvaporizing liquid titanium tetrachloride to form gaseous titaniumtetrachloride are known to those skilled in the art with the benefit ofthis disclosure. As understood by those skilled in the art with thebenefit of this disclosure, the vaporizer 290 is operated underconditions sufficient to vaporize liquid titanium tetrachloride to formgaseous titanium tetrachloride. Gaseous titanium tetrachloride in thevaporizer 290 is discharged from the vaporizer 290 and conducted to themetal chloride generator 220.

For example, the metal chloride centrifugal reactor 220 can be the metalchloride generator 10 described above and shown by FIGS. 1-8. Theremainder of this description of the process disclosed herein isdirected to the process wherein the metal chloride centrifugal reactor220 is the metal chloride generator 10 described above and shown byFIGS. 1-8.

Metal particles and chlorine are conducted to and introduced into themetal chloride generator 10 from sources thereof (not shown). Forexample, as shown by FIG. 9, all or a portion of the titaniumtetrachloride vapor formed in the vaporizer 112 can also conducted tothe metal chloride generator 10 to help dissipate the heat of thereaction in the metal chloride generator 10.

The titanium tetrachloride vapor, metal particles and chlorine areintroduced into the metal chloride generator 10 by feeding the metalparticles and chlorine into the reactant inlet conduit 50 of the metalchloride generator 10 through the first opening 54 of the reactant inletconduit 50 and discharging the metal particles and chlorine into theinterior 44 of the reaction chamber 28 of the generator 10 through thesecond opening 60 of the reactant inlet conduit 50. The type of metalparticles added to the metal chloride generator 10 will depend on thetype of metal chloride to be produced by the metal chloride generator10. For example, the metal particles introduced into the metal chloridegenerator can be formed of a metal selected from the group of aluminum,boron, zirconium, silicon and phosphorus. Particles (for example,pellets) formed of mixtures or alloys of the above metals includingaluminum-silicon alloys, aluminum-phosphorus alloys, aluminum-boronalloys, aluminum-zirconium alloys and combinations thereof can also bereacted with chlorine in the metal chloride generator to form mixedmetal chloride precursor compounds.

The size of the metal particles can vary. For example, the approximatediameter of the metal particles can be ¼^(th) or ⅜^(th) of an inch. Forexample, the metal particles introduced into the metal chloridegenerator 10 can be formed of aluminum so that aluminum chloride (AlCl₃)is generated in the generator 10. Aluminum chloride is known for itsability to promote rutilization of and enhance the durability oftitanium dioxide pigments. Aluminum pellets having ¼^(th) inch or ⅜^(th)inch diameter are commercially available. Chopped aluminum pellets andaluminum grains having a size of 1-4 mm are also commercially available.

The reaction of chlorine and metal particles such as aluminum particlesto form a metal chloride such as aluminum chloride in the metal chloridegenerator 10 is very exothermic. By running the titanium tetrachloridevapor from the vaporizer 290 or other process equipment through thegenerator 10, some of the heat generated to produce metal chloride canbe absorbed. For example, the reaction of aluminum and chlorine is soexothermic that at typical addition levels, virtually the entiretitanium tetrachloride vapor stream is run through the metal chloridegenerator 10 to serve as a heat sink for the process to keep thereaction temperature under control as dictated by the melting point ofaluminum.

The metal chloride generator 10 is operated under conditions sufficientto cause metal particles and chlorine in the generator to be broughtinto contact with one another and react to form metal chloride. Thecentrifugal forces allow the solid metal particles and chlorine gas toreact while preventing unreacted metal particles from exiting thereactor as blow over. For example, the metal chloride formed in themetal chloride generator can be selected from the group of aluminumchloride (AlCl₃), boron trichloride (BCl₃), zirconium chloride (ZrCl₄),silicon chloride (SiCl₄) and phosphorus chloride (PCl₃). For example,the metal chloride formed the metal chloride generator can be aluminumchloride.

A mixed vapor stream including metal chloride formed in the generator 10and titanium tetrachloride vapor in the generator flows through thereaction product outlet conduit 62 of the generator through the firstopening 66 thereof, and is discharged from the reaction product outletconduit 62 through the second opening 68 thereof to a location 70outside of the reactor housing 12. As shown by FIG. 9A, for example, themixed vapor stream including metal chloride and titanium tetrachlorideare discharged from the generator 10 and conducted to and introducedinto the oxidizer 250.

Oxidizers useful for facilitating the oxidation of a titanium halide toform a titanium dioxide in a process for manufacturing titanium dioxideare known to those skilled in the art with the benefit of thisdisclosure. In addition to the mixed vapor stream including metalchloride and titanium tetrachloride that is introduced into the oxidizer250 from the metal chloride generator 10, oxidizing gas and, optionally,supplemental fuel, are also conducted to and introduced into theoxidizer 250. For example, the supplemental fuel can be propane. Thesupplemental fuel is added to the oxidizer in order to provide heat tohelp sustain the oxidation reaction.

Metal chloride from the metal chloride generator 10 can be conducted toand introduced into the oxidizer 250 in a predetermined amount that issufficient to promote rutilization of the titanium dioxide. The amountof metal oxide (for example, alumina) needed to promote rutilization ofthe titanium dioxide will vary depending on numerous factors known tothose skilled in the art with the benefit of this disclosure. Forexample, generally, the amount of metal oxide required to promoterutilization of the titanium dioxide is in the range of from about 0.3%to about 1.5% by weight based on the weight of the titanium dioxideparticles being produced. For example, a typical amount of aluminaintroduced to the oxidizer 250 is 1.0% by weight based on the weight ofthe titanium dioxide being produced.

The oxidizing gas conducted to and introduced into the oxidizer 250 canbe molecular oxygen (O₂). Alternatively, the oxidizing gas can be anoxygen-containing gas such as oxygen in a mixture with air (oxygenenriched air). The particular oxidizing gas employed will depend on anumber of factors including the size of the reaction zone within theoxidization reactor, the degree to which the titanium halide andoxygen-containing gas reactants are preheated, the extent to which thesurface of the reaction zone is cooled and the throughput rate of thereactants in the reaction zone. While the exact amounts of the titaniumtetrachloride and oxidizing gas reactants employed can vary widely andare not particularly critical, it is important that the oxidizing gasreactant be present in an amount at least sufficient to provide for astoichiometric reaction with the titanium tetrachloride. Generally, theamount of the oxidizing gas reactant employed will be an amount inexcess of that required for a stoichiometric reaction with the titaniumhalide reactant, for example, from about 5% to about 25% in excess ofthat required for a stoichiometric reaction.

An example of another component that can be advantageously introducedinto the oxidizer is a scouring agent. The scouring agent functions toclean the walls of the reactor and prevent fouling thereof. Examples ofscouring agents which can be used include, but are not limited to, sand,mixtures of titanium dioxide and water which are pelletized, dried andsintered, compressed titanium dioxide, rock salt, fused alumina,titanium dioxide and salt mixtures and the like. The molecular oxygen orother oxidizing gas, supplemental fuel (if used) and scouring agent (ifused) are conducted to the oxidizer 250 from sources thereof (notshown).

As known to those skilled in the art with the benefit of thisdisclosure, the oxidizer 250 is operated under conditions sufficient tooxidize titanium tetrachloride and metal chloride in the vapor phase toform titanium dioxide particles having a metal oxide incorporated intheir crystalline lattice structures, and gaseous reaction products. Forexample, the reaction is carried out at a temperature of at least 700°C. For example, the reaction can be carried out at a temperature in therange of from about 2000° C. to about 2800° C. Titanium dioxideparticles having a desired particle size can be produced. For example,the oxidation of titanium tetrachloride to form particulate solidtitanium dioxide and gaseous reaction products is exemplified byreaction (2) below:

TiCl₄+O₂→TiO₂+2Cl₂  (2)

The metal chloride is also oxidized in the oxidizer 250 to form a metaloxide, which is incorporated into the lattice structure of the titaniumdioxide. For example, aluminum chloride is oxidized in the oxidizer toform aluminum oxide or alumina (Al₂O₃). The amount of metal oxideincorporated into the lattice structure of the titanium dioxide istypically in the range of from about 0.5% to about 1.5% by weight basedon the weight of the titanium dioxide. Steps can be taken to control theparticle size of the titanium dioxide particles.

Prior to being introduced into the oxidizer 250, the titaniumtetrachloride and molecular oxygen or other oxidizing gas reactantstreams are typically preheated, for example, in shell and tube typepreheaters or a superheater (not shown). For example, the titaniumtetrachloride reactant stream can be preheated to a temperature in therange of from about 650° F. to about 1800° F. (for example, to atemperature in the range of from about 675° F. to about 750° F.). Themolecular oxygen or other oxidizing gas stream can be preheated to atemperature in the range of from about 750° F. to about 3400° F. (forexample, to a temperature in the range of from about 1740° F. to about1930° F.). If the titanium tetrachloride vapor stream is first runthrough the metal chloride generator 10, it may not need to bepreheated.

The preheated titanium tetrachloride and oxidizing gas streams arecharged to and introduced into the oxidizer 250 at high flow rates. Thepressure at which the oxidation reaction is carried out can vary widely,for example from about 3 psig to about 50 psig. For example, at apressure of 1 atmosphere (absolute), the oxidation reaction temperatureis typically in the range of from about 2300° F. to about 2500° F.

Upon discharge from the oxidizer 250, the titanium dioxide particles andgaseous reaction products are conducted to and introduced into a heatexchanger 292 (for example, a tubular heat exchanger) where they arecooled by heat exchange with a cooling medium (such as cooling water) toa temperature of about 1300° F. A scouring agent can also be injectedinto the heat exchanger to remove deposits of titanium dioxide and othermaterials from the inside surfaces of the heat exchanger. The same typesof scouring agents that are used in the oxidizer 250 can be used in theheat exchanger 292.

After passing through the heat exchanger 292, the cooled titaniumdioxide particles and gaseous reaction products are conducted to a gassolid separator 296. In the separator 296, the particulate solidtitanium dioxide is separated from the gaseous reaction products andscouring agent (if used). The separated gaseous reaction products can berecycled for use in the process. For example, as shown by FIG. 9, thechlorine gas is recycled from the separator 296 to the chlorinator 200.The majority of the chlorine used in the process can be recovered.

The particulate titanium dioxide separated in the separator 296 is thenconducted to and introduced into pigment finishing process equipment298. For example, the titanium dioxide particles can be subject tovarious surface treatments, milled and dried. For example, depending onthe anticipated end use application, the finishing process typicallyentails coating the titanium dioxide particles with one or more metaloxides such as alumina and silica to enhance the light scatteringefficiency and durability of the pigment and impart other desiredproperties and characteristics thereto. The process equipment 298includes the necessary equipment to carry out one or more of thesesteps.

The sequence of the various process steps shown by FIG. 9 can be varied.For example, metal chloride formed in the generator 10 can be mixed withpurified titanium halide from the process equipment 280. The mixture ofmetal chloride and purified titanium halide can then be vaporized in thevaporizer 290, preheated, and conducted to the oxidation reactor 250.The mixture can be preheated either before or after it is vaporized. Inthis embodiment, the metal chloride generator 10 is positioned upstreamin the process.

As shown by FIG. 10, in a second embodiment, the process formanufacturing titanium dioxide disclosed herein comprises:

-   -   a. introducing metal particles and chlorine into a metal        chloride generator 220, wherein the metal chloride generator 220        is a metal chloride centrifugal reactor;    -   b. operating the metal chloride generator under conditions        sufficient to cause metal particles and chlorine in the        generator to be brought into contact with one another and react        using centrifugal force to form metal chloride;    -   c. introducing titanium halide, metal chloride formed in the        metal chloride generator 220 and oxygen into an oxidizer 250;    -   d. operating the oxidizer 250 under conditions sufficient to        oxidize titanium halide and metal chloride in the oxidizer 250        to form titanium dioxide particles having a metal oxide        incorporated into their crystalline lattice structure and        gaseous reaction products; and    -   e. recovering titanium dioxide particles formed in the oxidizer        250.

In this embodiment, steps a.-e. above are carried out in the same manneras steps c.-g., as described above in connection with the firstembodiment of the process, except in addition to titanium tetrachloride,other titanium halides can be oxidized with the metal chloride to formthe titanium dioxide particles and otherwise used in the process. Also,the titanium halide vapor can come from any source. Subject to theseexceptions, the description of steps c.-g. above, including thedescription of FIG. 9 as it relates to steps c.-g. and the related,optional and other steps of the process that are described above inconnection with steps c.-g., the first embodiment, is incorporated intothis discussion of the second embodiment of the process disclosedherein.

For example, the metal chloride centrifugal reactor 220 can be the metalchloride generator 10 described above and shown by FIGS. 1-8. Thehalogen gas (which can be chlorine gas) separated from the titaniumdioxide particles in the separator 296 can be recycled for use in aprocess used to form the titanium halide vapor.

The titanium halide vapor added to oxidizer 250 (either directly or fromthe metal chloride generator 10) can be any of the known halides oftitanium, including titanium tetrachloride, titanium tetrabromide,titanium tetraiodide and titanium tetrafluoride. Preferably, thetitanium halide reactant is titanium tetrachloride.

For example, the process is carried out on a continuous basis.

It should be noted that the description herein of the process of thisdisclosure (both the first and second embodiment of the processdisclosed herein) illustrates use of the metal chloride generator 10 insitu in a process for manufacturing titanium dioxide. However, thedescription herein also illustrates use of the metal chloride generator10 to generate aluminum chloride in other types of processes as well.The metal chloride generator 10 can be used to form various metalchlorides including aluminum chloride, boron trichloride, zirconiumchloride, silicon chloride, phosphorus chloride and mixtures of suchcompounds. Although the heat of the reaction may vary with thereactants, the basic process for generating all of these compounds isthe same.

EXAMPLE

The following example illustrates specific embodiments consistent withthe present disclosure but do not limit the scope of the disclosure orthe appended claims. Concentrations and percentages are by weight unlessotherwise indicated.

Example 1

Cold flow testing of a full scale model of the metal chloride generator10 described above was tested for its ability to produce aluminumchloride for use in a continuous chloride process for the manufacture oftitanium dioxide. For example, tests were carried out on an embodimentof the model wherein the second opening 60 of the reactant inlet conduit50 opened into the top half 46 of the interior 44 of the reactionchamber 28, as shown by FIGS. 1, 2A, 2B, 2C and 3. Tests were alsocarried out on an embodiment of the model wherein the second opening 60of the reactant inlet conduit 50 opened into the bottom half 48 of theinterior 44 of the reaction chamber 28, as shown by FIGS. 2D and 2E.

Also, in carrying out the tests, the distance that the reaction productoutlet conduit 62 extended into the interior 44 of the reaction chamber28, was varied to change the position of the first opening 66 within theinterior 44 of the reaction chamber 28. For example, in some tests, thefirst opening 66 of the reaction product outlet conduit 62 was flushwith the top 36 of the reaction chamber 28 as shown by FIGS. 2A, 2D and3 (in other words, the reaction product outlet conduit 62 did not extendinto the interior 44 of the reaction chamber 28). In other tests, thereaction product outlet conduit 62 extended less than half way into theinterior 44 of the reaction chamber 28 such that the first opening 66 ofthe reaction product outlet conduit 62 was positioned within the tophalf 46 of the interior 44 of the reaction chamber 28, as shown by FIGS.2B and 2E. In yet other tests, the reaction product outlet conduit 62extended more than half way into the interior 44 of the reaction chamber28 such that the first opening 66 of the reaction product outlet conduit62 was positioned within the bottom half 48 of the interior 44 of thereaction chamber 28, as shown by FIG. 2C.

Overall, the tests were successful. The cold flow testing of the fullscale model of the metal chloride generator 10 confirmed that thegenerator can successfully produce aluminum chloride for use in acontinuous chloride process for the manufacture of titanium dioxide.Based on the tests, it was concluded that in some respects, it is betterfor the second opening 60 of the reactant inlet conduit 50 to open intothe top half 46 of the interior 44 of the reaction chamber 28. Forexample, the gas flow from the second opening 60 into the reactionchamber 28 tended to cause a damming effect for the circulating pelletsor other particulates. The impact of such an effect was less bypositioning the second opening 60 to open into the top half 46 of theinterior 44 of the reaction chamber 28. It was also concluded that itmay work best in some cases for the reaction product outlet conduit toextend less than half way into the interior 44 of the reaction chamber28 such that the first opening 66 of the reaction product outlet conduit62 is positioned within the top half 46 of the interior 44 of thereaction chamber 28. Extending the reaction product outlet conduit 62too deep into the reaction chamber 28 tended to cause the metal pelletsor other particulates circulating in the reaction chamber to be caughtup in the outflow through the outlet conduit 62. In fact, in many cases,it may work best for the first opening 66 of the reaction product outletconduit 62 to be flush with the top 36 of the reaction chamber 28, thatis, for reaction product outlet conduit 62 not to extend into theinterior 44 of the reaction chamber 28. In other words, in many cases,it may be best not to have a vortex finder at all.

Therefore, the present disclosure is well adapted to attain the ends andadvantages mentioned, as well as those that are inherent therein. Theparticular embodiments disclosed above are illustrative only, as thepresent disclosure may be modified and practiced in different, butequivalent, manners apparent to those skilled in the art having thebenefit of the teachings herein. Furthermore, no limitations areintended to the details of construction or design herein shown, otherthan as described in the claims below. It is therefore evident that theparticular illustrative examples disclosed above may be altered ormodified, and all such variations are considered within the scope andspirit of the present disclosure. While apparatus and methods may bedescribed in terms of “comprising,” “containing,” “having,” or“including” various components or steps, the apparatus and methods canalso, in some examples, “consist essentially of” or “consist of” thevarious components and steps. Whenever a numerical range with a lowerlimit and an upper limit is disclosed, any number and any included rangefalling within the range are specifically disclosed. In particular,every range of values (of the form, “from about a to about b,” or,equivalently, “from approximately a to b,” or, equivalently, “fromapproximately a-b”) disclosed herein is to be understood to set forthevery number and range encompassed within the broader range of values.Also, the terms in the claims have their plain, ordinary meaning unlessotherwise explicitly and clearly defined by the specification.

What is claimed is:
 1. A metal chloride generator, comprising: a reactorhousing, said reactor housing including an inside surface, an outsidesurface, a top portion, a bottom portion, a sidewall connecting said topportion and said bottom portion together, and an interior; a cylindricalreaction chamber positioned within said interior of said reactorhousing, said reaction chamber including an inside surface, an outsidesurface, a top, a bottom, a cylindrical side wall connecting said topand said bottom together and an interior, said interior of said reactionchamber having a top half and a bottom half; a reactant inlet conduitextending through said sidewall of said reactor housing and saidsidewall of said reaction chamber and including an inside surface, anoutside surface and an interior, said reactant inlet conduit alsoincluding a first opening for receiving at least one reaction componentfrom a location outside of said reactor housing and a second opening fordischarging said reaction component into said reaction chamber, saidsecond opening of said reactant inlet conduit being flush with saidinside surface of said cylindrical sidewall of said reaction chamber andopening into said interior of said reaction chamber; and a reactionproduct outlet conduit extending through said top of said reactionchamber and said top of said reactor housing and including an insidesurface, an outside surface and an interior, said reaction productoutlet conduit also including a first opening for receiving at least onereaction product from said interior of said reaction chamber and asecond opening for discharging said reaction product to a locationoutside of said reactor housing.
 2. The metal chloride generator ofclaim 1, wherein said second opening of said reactant inlet conduitopens into said top half of said interior of said reaction chamber. 3.The metal chloride generator of claim 1, wherein said second opening ofsaid reactant inlet conduit opens into said bottom half of said interiorof said reaction chamber.
 4. The metal chloride generator of claim 1,wherein said first opening of said reaction product outlet conduit isflush with said top of said reaction chamber.
 5. The metal chloridegenerator of claim 1, wherein said reaction product outlet conduitextends from said top of said reaction chamber into said interior ofsaid reaction chamber such that said first opening of said reactionproduct outlet conduit is positioned within said interior of saidreaction chamber.
 6. The metal chloride generator of claim 5, whereinsaid reaction product outlet conduit extends less than half way intosaid interior of said reaction chamber such that said first opening ofsaid reaction product outlet conduit is positioned within said top halfof said interior of said reaction chamber.
 7. The metal chloridegenerator of claim 5, wherein said reaction product outlet conduitextends more than half way into said interior of said reaction chambersuch that said first opening of said reaction product outlet conduit ispositioned within said bottom half of said interior of said reactionchamber.
 8. The metal chloride generator of claim 6, wherein at leastone of said reaction chamber, said reactant inlet conduit, and saidreaction product outlet conduit includes a refractory lining attached tosaid inside surface thereof, said refractory lining having an insidesurface facing said interior of said reaction chamber, reactant inletconduit, or reaction product outlet conduit that has a texture roughenough to break up metal oxide layers on said metal particles.
 9. Themetal chloride generator of claim 8, wherein said inside surface of saidrefractory lining has a surface roughness in the range of from about0.01 μm to about 1000 μm.
 10. The metal chloride generator of claim 8,wherein said refractory lining is formed of a ceramic material.
 11. Themetal chloride generator of claim 10, wherein said refractory lining isformed of a silicon carbide ceramic material.